Electrolyzer cell arrangement

ABSTRACT

Some embodiments of the present invention provide electrolyzer cells in which distribution of water over the surface of an electrolyte layer (e.g. a MEA) is improved. Specifically, some embodiments provide an electrolyzer cell, including a flow field plate arranged in combination with at least two porous metal layers having smooth and flat surfaces, in which water is more uniformly distributed across an active surface of an electrolyte layer, which in turn may lead to a more uniform reaction rate over the active area of the electrolyte layer. Other related embodiments also include simplifications that may reduce costs related to manufacturing and assembly of electrochemical cells.

PRIORITY CLAIM

This application claims the benefit, under 35 USC 119(e), of U.S. Provisional Application Nos. 60/504,220 and 60/504,223 which were filed on Sep. 22, 2003; and, the entire contents of each of the U.S. Provisional Application Nos. 60/504,220 and 60/504,223 are hereby incorporated by reference. Moreover, this application is also a continuation-in-part of U.S. Application No. [Attorney Ref: 9351-444], entitled “Flow Field Plate Arrangement”, which was filed on Aug. 13, 2004, and the entire contents of which is also hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to electrochemical cells, and, in particular to various arrangements of electrolyzer cells.

BACKGROUND OF THE INVENTION

An electrolyzer cell is a type of electrochemical cell that uses electricity to electrolyze water (H₂O) into hydrogen (H₂) and oxygen (O₂). Generally, an electrolyzer includes an anode electrode, a cathode electrode and an electrolyte layer arranged between the anode and cathode electrodes. The specific arrangement of a particular electrolyzer cell is dependent upon the components, materials and technology employed. For example, in a Proton Exchange Membrane (PEM) electrolyzer cell the electrolyte layer is a proton exchange membrane arranged within a Membrane Electrode Assembly (MEA).

In conventional electrolyzer cell designs, the anode and cathode include multiple layers of woven metal screens, meshes or the like. The screens distribute electrical charge over the surface of the electrolyte layer (e.g. a MEA) where the electrolysis reactions occur. These conventional electrolyzer cells are arranged such that, in operation, water is introduced at the edges of the screens and is expected to distribute throughout the area occupied by screens because the screens are relatively porous. However, the lateral distribution of water is impeded by the entangled edges of the screens. For similar reasons, the screens also impede the evacuation of product gases from the surface of the electrolyte layer where the electrolysis reactions occur. Thus, due in part to the impediments to flow introduced by the layers of woven screens, a conventional electrolyzer cell inherently includes areas of restricted flow that limit water and product gas flow which, in turn results in a poor use of the available reaction area, occasional flooding and/or poisoning. Understandably, efficiency and overall performance is typically reduced as a result.

In other electrolyzer cell designs flow field plates are employed in place of the layers of woven metal screens. In such arrangements process gases/fluids are supplied to and evacuated from the vicinity of the electrolyte layer through a flow field structure arranged on the front surface of a particular flow field plate. Typically, a Gas Diffusion Media (GDM) is also included in between a flow field plate and a MEA. However, for PEM electrolyzer cells, the contact resistance between a flow field plate and a MEA is typically high which is undesirable. It is also difficult to control the flow, pressure and temperature of the process gases/fluids across most flow field plates, since conventional flow field structures provide numerous places for water and contaminants to accumulate, increasing the risk of flooding and/or poisoning an electrolyzer cell.

SUMMARY OF THE INVENTION

According to an aspect of an embodiment of the invention there is provided an electrolyzer cell including: an anode flow field plate; a cathode flow field plate; an electrolyte layer arranged between the anode and cathode flow field plates; and, first and second flat screens arranged between the anode flow field plate and the electrolyte layer, wherein each of the screens has a respective number of openings and is electrically conductive.

In some embodiments the first screen is adjacent the electrolyte layer and the openings of the first screen are smaller than those of the second screen. In some related embodiments, the spacing between the openings of the first screen is less than the spacing between the openings of the second screen.

In some embodiments, the openings of the first and second screens have a shape that is at least one hexagonal, circular, square, and triangular.

In some embodiments an electrolyzer cell has at least one of the anode flow field plate and the cathode flow field plate that includes: a plurality of manifold apertures; a flow field, fluidly connecting two of the manifold apertures, having a plurality of open-faced flow channels that are all substantially the same length and arranged to uniformly distribute both a first process gas/fluid and heat produced by an electrochemical reaction involving the first process gas/fluid over an area covered by the flow field. In some related embodiments some of the manifold apertures have the same area. In some related embodiments some of the manifold apertures have the same dimensions.

In some embodiments, the anode and cathode flow field plates are circular in shape and each has a central region and a peripheral region surrounding the central region, wherein a flow field is arranged within the central region and the plurality of manifold apertures are arranged in the peripheral region. In some related embodiments the open-faced flow channels include, in sequence, a first straight portion in fluid communication with a first one of the manifold apertures, a tortuous portion, an arc portion, and a second straight portion in fluid communication with a second one of the manifold apertures.

In some embodiments the anode and cathode flow field plates are rectangular in shape and the open-faced channels are comprised of a plurality of substantially straight and parallel primary flow channels that extend along the length of the flow field plate.

In some embodiments some of the manifold apertures are used to supply or evacuate process gases/fluids and each of these manifold apertures has substantially the same area as the other manifold apertures also used to supply or evacuate process gases/fluids. In some related embodiments all of the manifold apertures used to supply or evacuate respective process gases/fluids also have substantially identical dimensions.

In some embodiments, at least one of the anode and cathode flow field plates includes a coolant flow field, on a rear surface, having a plurality of open-faced flow channels that are all substantially the same length and arranged to uniformly distribute coolant on the rear surface.

In some embodiments at least one of the anode and cathode flow field plates comprises: a first slot, extending through the flow field plate, that is in fluid communication with open-faced flow channels on a front surface and in fluid communication with a first manifold aperture on a rear surface; and, a second slot, extending through the flow field plate, that is in fluid communication with the open-faced flow channels on the front surface and in fluid communication with a second manifold aperture on the rear surface. In some related embodiments, at least one of the anode and cathode flow field plates also includes: a first set of aperture extensions extending from the first manifold aperture to the first slot, over a portion of the rear surface; and, a second set of aperture extensions extending from the second manifold aperture to the second slot, over a portion of the rear surface.

According to aspects of another embodiment of the invention there is provided an electrochemical cell that includes: a first flow field plate; a second flow field plate; an electrolyte layer arranged between the first and second flow field plates; and, first and second flat screens arranged between the first flow field plate and the electrolyte layer, wherein each of the screens has a respective number of openings.

According to aspects of another embodiment of the invention there is provided an electrochemical cell stack, having at least one electrochemical cell including: a first flow field plate; a second flow field plate; an electrolyte layer arranged between the first and second flow field plates; and, first and second flat screens arranged between the first flow field plate and the electrolyte layer, wherein each of the screens has a respective number of openings.

In some embodiments at least one of the first and second flow field plates also includes: a plurality of manifold apertures; and, a flow field, fluidly connecting two of the manifold apertures, having a plurality of open-faced flow channels that are all substantially the same length and arranged to uniformly distribute both a first process gas/fluid and heat produced by an electrochemical reaction involving the first process gas/fluid over an area covered by the flow field. In some related embodiments, some of the manifold apertures have the same area.

In some related embodiments, the first and second flow field plates are circular in shape and each has a central region and a peripheral region surrounding the central region, wherein a flow field is arranged within the central region and the plurality of manifold apertures are arranged in the peripheral region. In some related embodiments each of the open-faced flow channels include, in sequence, a first straight portion in fluid communication with a first one of the manifold apertures, a tortuous portion, an arc portion, and a second straight portion in fluid communication with a second one of the manifold apertures.

In some embodiments the first and second flow field plates are rectangular in shape and the open-faced flow channels are comprised of a plurality of substantially straight and parallel primary flow channels that extend along the length of the flow field plate.

In some embodiments, some of the manifold apertures are used to supply or evacuate process gases/fluids and each of these manifold apertures has substantially the same area as the other manifold apertures also used to supply or evacuate process gases/fluids. In some related embodiments, all of the manifold apertures used to supply or evacuate respective process gases/fluids also have substantially identical dimensions.

In some embodiments, at least one of the first and second flow field plates also includes a coolant flow field, on a rear surface, having a plurality of open-faced flow channels that are all substantially the same length and arranged to uniformly distribute coolant on the rear surface

In some embodiments, at least one of the first and second flow field plates also includes: a first slot, extending through the flow field plate, that is in fluid communication with open-faced flow channels on a front surface and in fluid communication with a first manifold aperture on a rear surface; and, a second slot, extending through the flow field plate, that is in fluid communication with the open-faced flow channels on the front surface and in fluid communication with a second manifold aperture on the rear surface

Other aspects and features of the present invention will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings that illustrate aspects of embodiments of the present invention and in which:

FIG. 1 is a simplified schematic drawing of an electrolyzer cell module;

FIG. 2 is an exploded perspective view of an electrolyzer cell module;

FIG. 3A is a schematic drawing of a front surface of an anode flow field plate according to aspects of an embodiment of the invention;

FIG. 3B is a schematic drawing of a rear surface of the anode flow field plate illustrated in FIG. 3A;

FIG. 3C is an enlarged partial view of a water manifold aperture and adjacent parts on the front surface of the anode flow field plate illustrated in FIG. 3A;

FIG. 3D is an enlarged partial sectional view of the anode flow field plate taken along line A-A in FIG. 3C;

FIG. 3E is an enlarged partial sectional view of the anode flow field plate taken along line B-B in FIG. 3C;

FIG. 3F is an enlarged partial view of a coolant manifold aperture and adjacent parts on the rear surface of the anode flow field plate illustrated in FIG. 3B;

FIG. 3G is an enlarged partial sectional view of the anode flow field plate taken along line C-C in FIG. 3F;

FIG. 3H is an enlarged partial perspective view of another water manifold aperture and adjacent parts on the rear surface of the anode flow field plate illustrated in FIG. 3B;

FIG. 4 is a schematic drawing of a front surface of a corresponding cathode flow field plate suited for use with the anode flow field plate illustrated in FIG. 3A, according to aspects of an embodiment of the invention; and

FIG. 5 is an enlarged simplified sectional view of an electrolyzer cell according to aspects of an embodiment of the invention;

FIG. 6A is a schematic drawing of the top surface of a first screen suitable for use in an electrolyzer cell according to aspects of an embodiment of the invention;

FIG. 6B is a partial enlarged view of the first screen illustrated in FIG. 6A;

FIG. 7A is a schematic drawing of the top surface of a second screen suitable for use in an electrolyzer cell according to aspects of an embodiment of the invention; and

FIG. 7B is a partial enlarged view of the second screen illustrated in FIG. 7A.

DETAILED DESCRIPTION OF THE INVENTION

Some embodiments of the present invention provide electrolyzer cells in which distribution of water over the surface of an electrolyte layer (e.g. a MEA) is improved. Specifically, some embodiments provide an electrolyzer cell, including a flow field plate arranged in combination with at least two porous metal layers, in which water is more uniformly distributed across an active surface of an electrolyte layer, which in turn may lead to a more uniform reaction rate over the active area of the electrolyte layer. Other related embodiments, described below, also include simplifications that may reduce costs related to manufacturing and assembly of electrochemical cells.

Conventionally, anode flow field plates usually have a different configuration as compared to cathode flow field plates due to the different stoichiometries of process gases/fluids associated with each flow field plate. The different stoichiometries often require different amounts of each process gas/fluid to be accommodated on each respective flow field plate, which in turn requires the flow field channels on each respective plate to support more or less volume than a corresponding flow field plate on the other side of the electrolyte layer. A consequence of this is that the ribs that define the flow field structure on an anode flow field plate are often offset with those on a corresponding cathode flow field plate. Shearing forces resulting from the offset may damage an electrolyte membrane arranged between the flow field plates. The offset between the flow field plates may, in some specific instances, also impede the distribution of process gases/fluids within an electrochemical cell, thereby reducing efficiency. Another consequence is that the differences make the manufacturing and assembly of flow field plates complicated and costly.

Aspects of the flow field structures and plate arrangements according to examples described in the applicant's co-pending U.S. patent application Ser. No. 10/109,002 (filed 29-Mar.-2002) can be employed to provide reduced shearing forces on a membrane and simplify sealing between flow field plates. The entire contents of the applicant's co-pending U.S. patent application Ser. No. 10/109,002 are hereby incorporated by reference.

As disclosed in the applicant's co-pending U.S. patent application Ser. No. 10/109,002, after assembly, a substantial portion of the anode flow field channels and the cathode flow field channels are disposed directly opposite one another with an electrolyte membrane arranged between the two plates. Accordingly, a substantial portion of the ribs on the anode flow field plate match-up with a corresponding substantial portion of the ribs on the cathode flow field plate. This is described as “rib-to-rib” pattern matching hereinafter.

Aspects of flow field plate arrangements according to examples described in the applicant's co-pending U.S. patent application Ser. No. 09/855,018 (filed 15-May-2001) can also be employed to provide an effective sealing between flow field plates and an electrolyte membrane arranged between the two plates. The entire contents of the applicant's co-pending U.S. patent application Ser. No. 09/855,018 are hereby incorporated by reference.

As disclosed in the applicant's co-pending U.S. patent application Ser. No. 09/855,018, the inlet flow of a particular process gas/fluid from a respective manifold aperture does not take place directly over the front (active) surface of a flow field plate; rather, the process gas/fluid is first guided from the respective manifold aperture over a portion of the rear (passive) surface of the flow field plate and then through a “back-side feed” aperture extending from the rear surface to the front surface. A portion of the front surface defines an active area that is sealingly separated from the respective manifold aperture over the front surface when an electrochemical cell stack is assembled. The portion of the rear surface over which the inlet flow of the process gas/fluid takes place has open-faced gas/fluid flow field channels in fluid communication with the respective manifold aperture. The back-side feed apertures extend from the rear surface to the front surface to provide fluid communication between the active area and the open-faced gas/fluid flow field channels that are in fluid communication with the respective manifold aperture. Accordingly, as described in the examples provided in the applicant's co-pending U.S. patent application Ser. No. 09/855,018, a seal between the membrane and the flow field plate can be made in an unbroken path around the periphery of the membrane.

In prior art examples, the seal between the membrane and the active area on the front surface of the flow field plate, which is typically around the periphery of the membrane, is broken by the open-faced flow field channels leading up to respective manifold apertures from the active area on the front surface of the flow field plate. By contrast, according to the applicant's aforementioned co-pending application a process gas/fluid is fed to the active area on the front surface through back-side feed apertures from the rear surface of each flow field plate, and a sealing surface separates the back-side feed apertures and the respective manifold aperture(s) on the front surface of each flow field plate. This method of flowing fluids from a rear (passive or non-active) surface to the front (active) surface is referred to as “back-side feed” in the description. Those skilled in the art will appreciate that gases/fluids can be evacuated from the active area on the front surface to the rear surface and then into another manifold aperture in a similar manner.

Aspects of flow field plate arrangements according to examples described in the applicant's co-pending U.S. patent application Ser. No. 10/845,263 (filed 14-May-2004) can also be employed to provide an effective sealing between flow field plates and a membrane arranged between the two electrodes. The entire contents of the applicant's co-pending U.S. patent application Ser. No. 10/845,263 are hereby incorporated by reference.

As disclosed in the applicant's co-pending U.S. patent application Ser. No. 10/845,263, the inlet flow of a particular process gas/fluid from a respective manifold aperture does not take place directly over the front (active) surface of a flow field plate; rather, the process gas/fluid is first guided from the respective manifold aperture over a portion of an oppositely facing complementary active surface, included in an adjacent electrochemical cell, and then through a “complementary active-side feed” aperture extending through to the front surface of the flow field plate. According to examples described in the applicant's co-pending U.S. patent application Ser. No. 10/845,263 a seal between the membrane and the flow field plate can be made in an unbroken path around the periphery of the membrane, without requiring the flow field plate to have a passive surface, as in the examples described in the applicant's co-pending U.S. patent application Ser. No. 09/855,018.

Aspects of flow field plate arrangements according to examples described in the applicant's co-pending U.S. patent application Ser. No. 10/845,263 also provide for a symmetrical flow field plate arrangement that enables the use of a single flow field plate design for both anode and cathode flow field plates employed in an electrochemical cell stack. That is, in some embodiments, the anode and cathode flow field plates employed for use in an electrochemical cell stack are substantially identical.

Again, it was noted above that the various process gases/fluids, employed and produced within a particular electrochemical cell, typically have different stoichiometries relative to one another. Thus, as per convention, in order to optimize the performance of an electrochemical cell each respective manifold aperture provided on a flow field plate for a corresponding process gas/fluid is sized so that each process gas/fluid is supplied and/or evacuated in a manner relative to a corresponding stoichiometry.

For example, with respect to hydrogen-powered fuel cells, two hydrogen molecules are consumed for each oxygen molecule consumed. This requires more hydrogen to flow over a respective anode flow field plate than a corresponding stoichiometric amount of oxygen flowing over a corresponding cathode flow field plate. This is achieved by making the input and output manifold apertures for the hydrogen larger than those for the oxidant.

However, if air is used as the source of oxygen the aforementioned relative sizing is reversed. Air is only about 20% oxygen and so more air is needed to provide the required stiochiometric amount of oxygen than if pure oxygen is supplied. Accordingly, inlet and outlet manifold apertures for the oxidant are made larger than those for the hydrogen fuel.

In another example, with respect to water supplied electrolyzers, two hydrogen molecules (H₂) are produced for each oxygen (O₂) molecule produced. This results in more hydrogen flowing over a respective cathode flow field plate than a corresponding stoichiometric amount of oxygen flowing over a corresponding anode flow field plate. Typically, flow field plates adapted for use in electrolyzers have input and output manifold apertures for the hydrogen that are larger than those for the oxidant; and additionally, the widths of the flow field channels on the cathode flow field plate are made wider than the widths of the flow field channels on the anode flow field plate to accommodate the relatively larger volume of hydrogen on the cathode side of the electrolyte layer.

Aspects of flow field plate arrangements according to examples described in the applicant's co-pending U.S. patent application Ser. No. ______ [Attorney Ref: 9351-444] (filed 13-Aug.-2004) provide a number of manifold apertures, each for one of various process gases/fluids, that are the same size as one another. In other words, for example, the inlet manifold apertures provided for hydrogen and oxygen on a flow field plate have substantially the same area and in some specific embodiments they also have substantially identical dimensions. The entire contents of the applicant's co-pending U.S. patent application Ser. No. ______ [Attorney Ref: 9351-444] are hereby incorporated by reference. It is also noted that the applicant's co-pending U.S. patent application Ser. No. ______ [Attorney Ref: 9351-444] is based on the applicant's U.S. Provisional Application 60/495,092 (filed 15-Aug.-2003) that the present application has claimed the benefit of above.

Fuel cell reactions and electrolysis reactions are typically exothermic and temperature regulation is generally an important consideration in the design of an electrochemical cell stack, since the aforementioned reactions are temperature dependent. In particular, adequate temperature regulation provides a control point for the regulation of the desired electrochemical reactions; and, in some instances, helps to subdue undesired reactions that may occur. Heat can be carried away from electrochemical cells by process gases/fluids; yet, it is also often necessary to provide a separate coolant stream, that flows over the rear surfaces of the constituent flow field plates, to dissipate the heat generated during operation. Conventional temperature regulation schemes only take the overall electrochemical cell stack temperature into consideration. The temperatures in specific areas within an electrochemical cell (e.g. across different areas of a flow field plate) cannot be regulated, since conventional heat dissipation techniques do not enable such careful temperature control. In contrast to this, some embodiments of the present invention, described below with respect to FIGS. 3A-3H and 4, provide flow field plates with respective flow field structures arranged to evenly distribute heat across the surface of the flow field plates.

It is commonly understood that in practice a number of electrochemical cells, all of one type, can be arranged in stacks having common features, such as process gas/fluid feeds, drainage, electrical connections and regulation devices. That is, an electrochemical cell module is typically made up of a number of singular electrochemical cells connected in series to form an electrochemical cell stack. The electrochemical cell module also includes a suitable combination of associated structural elements, mechanical systems, hardware, firmware and software that is employed to support the function and operation of the electrochemical cell module. Such items include, without limitation, piping, sensors, regulators, current collectors, seals, insulators and electromechanical controllers.

As noted above, flow field plates typically include a number of manifold apertures that each serve as a portion of a corresponding elongate distribution channel for a particular process gas/fluid. In some embodiments, the cathode of an electrolyzer cell does not need to be supplied with an input process gas/fluid and only hydrogen gas and water need to be evacuated. In such electrolyzer cells a flow field plate does not require an input manifold aperture for the cathode but does require an output manifold aperture. By contrast, a typical embodiment of a fuel cell makes use of inlet and outlet manifold apertures for both the anode and the cathode. However, a fuel cell can also be operated in a dead-end mode in which process reactants are supplied to the fuel cell but not circulated away from the fuel cell. In such embodiments, only inlet manifold apertures are provided.

There are a number of different electrochemical cell technologies and, in general, this invention is expected to be applicable to all types of electrochemical cells. Very specific example embodiments of the invention have been developed for use with Proton Exchange Membrane (PEM) electrolyzer cells. Various other types of electrolyzer cells include, without limitation, Solid Polymer Water Electrolyzers (SPWE). Similarly, various types of fuel cells include, without limitation, Alkaline Fuel Cells (AFC), Direct Methanol Fuel Cells (DMFC), Molten Carbonate Fuel Cells (MCFC), Phosphoric Acid Fuel Cells (PAFC), Solid Oxide Fuel Cells (SOFC) and Regenerative Fuel Cells (RFC).

Referring to FIG. 1, shown is a simplified schematic diagram of a Proton Exchange Membrane (PEM) electrolyzer cell module, simply referred to as electrolyzer cell module 100 hereinafter, that is described herein to illustrate some general considerations relating to the operation of electrochemical cell modules. It is to be understood that the present invention is applicable to various configurations of electrochemical cell modules that each include one or more electrochemical cells. Those skilled in the art would appreciate that a PEM fuel cell module has a similar configuration to the PEM electrolyzer cell module 100 shown in FIG. 1.

The electrolyzer cell module 100 includes an anode electrode 21 and a cathode electrode 41. The anode electrode 21 includes a water input port 22 and a water/oxygen output port 24. Similarly, the cathode electrode 41 includes a water input port 42 and a water/hydrogen output port 44. An electrolyte membrane 30 is arranged between the anode electrode 21 and the cathode electrode 41.

The electrolyzer cell module 100 also includes a first catalyst layer 23 between the anode electrode 21 and the electrolyte membrane 30, and a second catalyst layer 43 between the cathode electrode 41 and the electrolyte membrane 30. In some embodiments the first and second catalyst layers 23, 43 are deposited on the anode and cathode electrodes 21, 41, respectively.

A voltage source 115 is coupled between the anode electrode 21 and the cathode electrode 41.

In operation, water is introduced into the anode electrode 21 via the water input port 22. The water is dissociated electrochemically according to reaction (1), given below, in the presence of the electrolyte membrane 30 and the first catalyst layer 23. H₂O→2H⁺+2e ⁻+½O₂  (1) The chemical products of reaction (1) are hydrogen ions (i.e. cations), electrons and oxygen. The hydrogen ions pass through the electrolyte membrane 30 to the cathode electrode 41 while the electrons are drawn through the voltage source 115. Water containing dissolved oxygen molecules is drawn out through the water/oxygen output port 24.

Simultaneously, additional water is introduced into the cathode electrode 41 via the water input port 42 in order to provide moisture to the cathode side of the membrane 30.

The hydrogen ions (i.e. protons) are electrochemically reduced to hydrogen molecules according to reaction (2), given below, in the presence of the electrolyte membrane 30 and the second catalyst layer 43. That is, the electrons and the ionized hydrogen atoms, produced by reaction (1) in the anode electrode 21, are electrochemically consumed in reaction (2) in the cathode electrode 41. 2H₂ ⁺+2e ⁻→H₂  (2)

The water containing dissolved hydrogen molecules is drawn out through the water/hydrogen output port 44. The electrochemical reactions (1) and (2) are complementary to one another and show that for each oxygen molecule (O₂) that is electrochemically produced two hydrogen molecules (H₂) are electrochemically produced.

In a similarly configured PEM fuel cell the reactions (2) and (1) are respectively reversed in the anode and cathode. This is accomplished by replacing the voltage source 115 with a load and supplying hydrogen to the anode electrode 21 and oxygen to the cathode electrode 41. The load is coupled to employ a generated electric potential that is of the opposite polarity to that shown on the anode and cathode electrodes 21 and 41, respectively, of FIG. 1. The products of such a PEM fuel cell include water, heat and an electric potential.

Referring now to FIG. 2, illustrated is an exploded perspective view of an electrolyzer cell module 100′. For the sake of brevity and simplicity, only the elements of one electrochemical cell are shown in FIG. 2. That is, the electrolyzer cell module 100′ includes only one electrolyzer cell; however, an electrolyzer cell stack will usually include a number of electrolyzer cells stacked together. The electrolyzer cell of the electrolyzer cell module 100′ comprises an anode flow field plate 120, a cathode flow field plate 130, and a Membrane Electrode Assembly (MEA) 124 arranged between the anode and cathode flow field plates 120, 130. Again, the designations “front surface” and “rear surface” with respect to the anode and cathode flow field plates 120, 130 indicate their respective orientations with respect to the MEA 124. The “front surface” of a flow field plate is the side facing towards the MEA 124, while the “rear surface” faces away from the MEA 124.

Briefly, each flow field plate 120, 130 has an inlet region and an outlet region. In this particular embodiment, for the sake of clarity, the inlet and outlet regions are placed on opposite ends of each flow field plate, respectively. However, various other arrangements are also possible. Each flow field plate 120, 130 also includes a number of open-faced flow channels that fluidly connect the inlet to the outlet regions and provide a structure for distributing the process gases/fluids to the MEA 124. Examples of anode flow field plates according to aspects of embodiments of the invention will be described below with reference to FIGS. 3A-3H. An example of a cathode flow field plate according to the aspects of an embodiment of the invention will be described in detail below with reference to FIG. 4.

The MEA 124 includes a solid electrolyte (e.g. a proton exchange membrane) 125 arranged between an anode catalyst layer (not shown) and a cathode catalyst layer (not shown).

The electrolyzer cell of the electrolyzer cell module 100′ also includes a first Gas Diffusion Media (GDM) 122 that is arranged between the anode catalyst layer and the anode flow field plate 120, and a second GDM 126 that is arranged between the cathode catalyst layer and the cathode flow field plate 130. The GDMs 122, 126 facilitate the diffusion of the process fluids and gases to the catalyst surfaces of the MEA 124. The GDMs 122, 126 also enhance the electrical conductivity between each of the anode and cathode flow field plates 120, 130 and the solid electrolyte 125 (e.g. a proton exchange membrane).

The elements of the electrolyzer cell are enclosed by supporting elements of the electrolyzer cell module 100′. Specifically, the supporting elements of the electrolyzer cell module 100′ include an anode endplate 102 and a cathode endplate 104, between which the electrolyzer cell and other elements are appropriately arranged. In the present embodiment, the cathode endplate 104 is provided with connection ports for supply and evacuation of process gases/fluids. The connection ports will be described in greater detail below.

Other elements arranged between the anode and cathode endplates 102, 104 include an anode insulator plate 112, an anode current collector plate 116, a cathode current collector plate 118 and a cathode insulator plate 114, respectively. In different embodiments varying numbers of electrochemical cells are arranged between the current collector plates 116, 118. In such embodiments the elements that make up each electrochemical cell are appropriately repeated in sequence to provide an electrochemical cell stack that produces the desired output. In many embodiments a sealing means is provided between plates as required to ensure that the various process gases/fluids are isolated from one another.

In order to hold the electrolyzer cell module 100′ together, tie rods 131 are provided that are screwed into threaded bores in the anode endplate 102 (or otherwise fastened), passing through corresponding plain bores in the cathode endplate 104. Nuts and washers or other fastening means are provided, for tightening the whole assembly and to ensure that the various elements of the individual electrochemical cells are held together.

As noted above various connection ports to an electrochemical cell stack are included to provide a means for supplying and evacuating process gases, fluids, coolants etc. In some embodiments, the various connection ports to an electrochemical cell stack are provided in pairs. One of each pair of connection ports is arranged on a cathode endplate (e.g. cathode endplate 104) and the other is appropriately placed on an anode endplate (e.g. anode endplate 102). In other embodiments, the various connection ports are only placed on either the anode or cathode endplate. It will be appreciated by those skilled in the art that various arrangements for the connection ports may be provided in different embodiments of the invention.

With continued reference to FIG. 2, the cathode endplate 104 has first and second water/oxygen connection ports 106, 107, first and second coolant connection ports 108, 109, and first and second water/hydrogen connection ports 110, 111. The ports 106-111 are arranged so that they will be in fluid communication with manifold apertures included on the MEA 124, the first and second gas diffusion media 122, 126, the anode and cathode flow field plates 120, 130, the first and second current collector plates 116, 118, and the first and second insulator plates 112, 114. The manifold apertures on all of the aforementioned plates align to form three sets of elongate inlet and outlet channels.

The electrolyzer cell module 100′ is operable to facilitate a catalyzed reaction. As described above, water is dissociated at the anode catalyst layer of the MEA 124 to form protons, electrons and oxygen molecules. The solid electrolyte (e.g. proton exchange membrane) 125 facilitates migration of the protons from the anode catalyst layer to the cathode catalyst layer. Most of the free electrons will not pass through the solid electrolyte 125, and instead flow through a voltage source (e.g. voltage source 115 in FIG. 1) via the current collector plates 116, 118, as a result of an electromotive force provided by the voltage source. With the cathode catalyst layer of the MEA 124, protons and electrons are reduced to hydrogen molecules, according to reaction (2). The oxygen and hydrogen produced at the anode and cathode respectively are dissolved in water supplied to the electrodes. The oxygen and hydrogen remain dissolved as long as the respective water/gas streams remain pressurized.

Simultaneously, a coolant flow through the electrolyzer cell module 100′ is provided to the electrolyzer cell(s) via connection ports 108, 109 and coolant manifold apertures in the aforementioned plates. As the electrolyzer cell reaction is exothermic and the reaction rate is sensitive to temperature, the flow through of coolant takes away the heat generated in the electrolyzer cell reactions, preventing the temperature of the fuel cell stack from increasing, thereby regulating the electrolyzer cell reactions to a stable level. The coolant is a gas or fluid that is capable of providing a sufficient heat exchange that will permit cooling of the stack. Examples of known coolants include, without limitation, water, deionized water, oil, ethylene glycol, and propylene glycol. Some embodiments of electrolyzer cells do not require a separate coolant stream since the water supplied to the anode and cathode electrodes provides a sufficient amount of heat dissipation from the electrolyzer cell(s).

The flow field plates 120, 130 shown in FIG. 2 are rectangular. In other embodiments of the invention, flow field plates can be any shape suitable for a particular design of an electrochemical cell stack. As another example, the flow field plates described below with reference to FIGS. 3A-3H and FIG. 4 are circular. These flow field plates are not suitable for use in the electrolyzer cell module 100′ illustrated in FIG. 2 only because their shape is circular and not rectangular.

Referring now to FIG. 3A, illustrated is a front surface of a circular anode flow field plate 220. The front surface of the anode flow field plate 220 has a central region 201 and a peripheral region 202 surrounding the central region 201.

In this particular embodiment, the peripheral region 202 includes six manifold apertures. Three of the six manifold apertures are used for inputs. There is an anode water inlet manifold aperture 136, an anode coolant inlet manifold aperture 138, and a second anode water inlet manifold aperture 140. The other three manifold apertures are used for complementary outputs. There is an anode water/oxygen outlet manifold aperture 137, an anode coolant outlet manifold aperture 139 and an anode water/hydrogen outlet manifold aperture 141. In some embodiments, the second anode water inlet manifold aperture 140 and the water/hydrogen outlet manifold aperture 141 are both used as outputs for hydrogen produced in a respective electrolyzer cell.

In contrast to a conventional design, the anode water/oxygen manifold apertures 136, 137 have substantially the same areas as the anode water/hydrogen manifold apertures 140, 141, respectively. In some embodiments, as is shown in FIG. 3A, the anode water/oxygen manifold apertures 136, 137 have substantially the same areas as one another as well. The anode coolant manifold apertures 138, 139 are also the same size as the manifold apertures 136, 137 and 140, 141. It should be noted that the relative sizing of the manifold apertures with respect to one another is not essential and that each may be a different size depending upon the requirements of a particular application. However, in some applications, making all of the manifold apertures the same size does simplify the design of a flow field plate and possibly reduces associated manufacturing and assembly costs.

The peripheral region also includes a number of through holes 221 to accommodate tie rods (not shown) used to assemble an electrolyzer cell module.

Referring now to FIGS. 3C-3E, and with further reference to FIG. 3A, the central region 201 of the front surface of the anode flow field plate 220 includes a water flow field 132. The water flow field 132 includes a number of open-faced channels that fluidly connect the water inlet manifold aperture 136 to the water/oxygen outlet manifold aperture 137. However, in this embodiment, water cannot flow directly from the inlet manifold aperture 136 to the flow field 132 over the front surface of the anode flow field plate 220; nor can water/oxygen flow from the flow field 132 directly to the outlet manifold aperture 137 over the front surface of the anode flow field plate 220. The present embodiment of the invention, illustrated in FIGS. 3A-3H, advantageously employs “back-side feed” as described in the applicant's co-pending U.S. application Ser. No. 09/855,018, which was incorporated by the reference above. A water/oxygen flow between the flow field 132 and the manifold apertures 136, 137 will be described in more detail below.

A sealing surface 200 is provided around the flow field 132, the various manifold apertures 136-141 and the through holes 221 to accommodate a seal that is employed to prevent leaking and mixing of process gases/fluids. The sealing surface 200 is formed completely enclosing the flow field 132 and the various manifold apertures 136-141. In this particular embodiment, the sealing surface 200 is meant to completely separate the various manifold apertures 136-141 from one another and the flow field 132 on the front surface of the anode flow field plate 220. In some embodiments, the sealing surface 200 may have a varied depth (in the direction perpendicular to the plane of FIG. 3A) and/or width (in the plane of FIG. 3A) at different positions around the anode flow field plate 220. In other embodiments, the sealing surface 200 may be flush with the front surface.

In this particular embodiment, the sealing surface 200 is bounded by a raised portion 223 around the outside edge of the flow field plate 220 and raised portions 222 around the inside edges of the various manifold apertures 136-141 and through holes 221.

Also included are sets of slots 280, 280′ that are respectively provided adjacent the water inlet manifold aperture 136 and the water/oxygen outlet manifold aperture 137. The slots 280, 280′ penetrate the thickness of the anode flow field plate 220, thereby fluidly connecting the front and rear surfaces of the anode flow field plate 220. Each set of slots 280, 280′ is shown as a collection of multiple apertures. However, in other embodiments each set of slots 280, 280′ can be provided as a single aperture. With reference to the applicant's co-pending U.S. application Ser. No. 09/855,018, the sets of slots 280, 280′ are otherwise known as “back-side feed” apertures.

With specific reference to FIGS. 3A and 3C, illustrated is one example pattern that can be employed for the water flow field 132 on the front surface of the anode flow field plate 220 according to aspects of an embodiment of the invention. The water flow field 132 includes a number of water flow channels 171 that are in fluid communication with the slots 280, 280′. The water flow channels 171 are defined by a respective number of ribs 172. In this particular embodiment, two water flow channels 171, defined by three ribs 172, fluidly connect two corresponding slots 280, 280′.

Each water flow channel 171 has a first straight portion 171 a, a tortuous portion 171 b, an arc portion 171 c and a second straight portion 171 d. The first and second straight portions 171 a, 171 d are in fluid communication with respective slots 280, 280′. In order to offset and accommodate all of the water flow channels 171, each of the portions 171 a, 171 b, 171 c and 171 d of any one of the water flow channels 171 extends to a different extent as respectively compared to those of a neighboring one of the water flow channels 171. For example, some of the water flow channels 171 have longer straight portions 171 a, 171 d and a shorter tortuous portion 171 b and a shorter arc portion 171 c, while others have shorter straight portions 171 a, 171 d and a longer tortuous portion 171 b and a longer arc portion 171 c. However, in order to achieve a substantially uniform heat distribution and, possibly, in turn a substantially uniform reaction rate over the flow field 132, water within each of the flow channels 171 is preferably subjected to substantially the same heat exchange history as water in any of the other flow channels 171. In some embodiments of the invention, this is accomplished by making all of the flow channels 171 substantially the same total length.

The rear surface of the anode flow field plate 220 is illustrated in FIG. 3B. In this particular embodiment, the rear surface of the anode flow field plate 220 includes an optional coolant flow field 144 having a number of open-faced flow channels. The coolant flow field 144 fluidly connects the anode coolant inlet manifold aperture 138 to the anode coolant outlet manifold aperture 139. The rear surface also includes a sealing surface 400 that separates the manifold apertures 136, 137, 140 and 141 from the coolant flow field 144 and the manifold apertures 138, 139. In some embodiments, within an assembled electrochemical cell, a seal is seated on the sealing surface 400 to prevent leaking or mixing of process gases/fluids.

The sealing surface 400 is defined by a raised portion 224 around each of the manifold apertures 136, 137, 140 and 141, and collectively around the coolant flow field 144 and the manifold apertures 138, 139. The sealing surface 400 may have varied depth and/or width at different positions around the anode flow field plate 220, as may be desired. However, whereas the sealing surface 200 on the front surface completely separates all of the various manifold apertures 136-141 from the water flow field 132, the sealing surface 400 only completely separates the manifold apertures 136, 137, 140 and 141 from the coolant flow field 144, permitting coolant to flow to and from the coolant flow field 144 via the manifold apertures 138, 139.

In other embodiments, for example air-cooled (i.e. air-breathing) electrochemical stacks, ambient air is used as a coolant. In such cases and in other embodiments, the coolant flow field 144 can be omitted.

Referring now to FIGS. 3B-3H, on the rear surface of the anode flow field plate 220, the manifold apertures 136, 137 each have a respective set of aperture extensions 281, 281′. Each set of aperture extensions 281, 281′ is provided with a respective set of protrusions 282, 282′ that extend between the corresponding slots 280, 280′. Each set of protrusions 282, 282′ defines a respective set of flow channels 284, 284′. The sets of flow channels 284, 284′ stop short of the corresponding edges of the manifold apertures 136, 137, respectively, thereby facilitating the water flow between the slots 280, 280′ and the corresponding manifold apertures 136, 137. The sealing surface 400 collectively separates the aperture extensions 281, 281′ and the slots 280, 280′ from the coolant flow field 144 and other manifold apertures 138-141.

The manifold apertures 140, 141 also have respective sets of aperture extensions 181, 181′. Each set of aperture extensions 181, 181′ is provided with a respective set of protrusions 182, 182′ that extend towards the corresponding manifold apertures 140, 141. Each set of protrusions 182, 182′ is manufactured such that they extend between corresponding slots 180, 180′ on a complementary configured cathode flow field plate 230 (shown in FIG. 4).

On the rear surface of the anode flow field plate 220 the sets of protrusions 182, 182′ define corresponding sets of flow channels 184, 184′ that stop short of the corresponding edges of the manifold apertures 140, 141, respectively, thereby facilitating the water/hydrogen flow between the respective slots 180, 180′ and the corresponding manifold apertures 140, 141. The sealing surface 400 collectively separates the aperture extensions 181, 181′ (and, eventually the respective slots 180, 180′) from the coolant flow field 144 and the other manifold apertures 136-139.

With specific reference to FIGS. 3B, 3F and 3G, illustrated is one example pattern that can be employed for the flow channels of the coolant flow field 144 on the rear surface of the anode flow field plate 220 according to aspects of an embodiment of the invention. Specifically, the coolant flow field 144 includes a number of coolant flow channels 191 that fluidly connect the coolant inlet manifold aperture 138 to the coolant outlet manifold aperture 139. The coolant flow channels 191 are defined by a respective number of ribs 192. In this particular embodiment, each of the coolant flow channels 191 are defined by two ribs 192. Each coolant flow channel 191 has a first straight portion 191 a, a tortuous portion 191 b, an arc portion 191 c and a second straight portion 191 d. The first and second straight portions 191 a and 191 d are in fluid communication with the coolant inlet aperture 138 and the coolant outlet aperture 139, respectively.

In order to offset and accommodate all of the coolant flow channels 191, each of the portions 191 a, 191 b, 191 c and 191 d of any one of the coolant flow channels 191 extends to a different extent as respectively compared to those of a neighboring one of the coolant flow channels 191. For example, some of the coolant flow channels 191 have longer straight portions 191 a and/or 191 d and a shorter tortuous portion 191 b and a shorter arc portion 191 c while others have shorter straight portions 191 a, 191 d and a longer tortuous portion 191 b and a longer arc portion 191 c. However, in order to achieve a substantially uniform heat distribution over the flow field 144, coolant in each of the flow channels 191 is preferably subjected to substantially the same heat exchange history as coolant in any of the other flow channels 191. In some embodiments of the invention, this is accomplished by making all of the flow channels 191 substantially the same total length.

In operation, water flows out from the water inlet manifold aperture 136 and through the flow channels 284 in the aperture extensions 281 on the rear surface of the anode flow field plate 220. At the end of the flow channels 284, water then flows through the slots 280 leaving the rear surface and entering the flow channels 171 on the front surface of the anode flow field plate 220. Specifically, water flows from the slots 280 into the first straight portions 171 a of the flow channels 171. The water then flows through the tortuous portions 171 b and arc portions 171 c, and subsequently through the second straight portions 171 d into the slots 280′. A combination of water and oxygen leaves the front surface of the anode flow field plate 220 via the slots 280′ and enters the flow channels 284′ of the aperture extensions 281′ on the rear surface. The combination of water and oxygen flows out of the flow channels 284′ and into the water/oxygen manifold aperture 137.

As the water flows along the flow channels 171, at least a portion of the water diffuses across a GDM and reacts at an anode catalyst layer of a MEA. Those skilled in the art will appreciate that the water that reacts at the anode catalyst layer does so by dissociating into hydrogen ions, free electrons, and oxygen molecules according to reaction (1) described above. The oxygen remains dissolved in the un-reacted water (since the water flow is usually pressurized) and is carried out of the flow channels 171. The hydrogen ions migrate across an electrolyte layer to a respective cathode flow field plate (e.g. as shown in FIG. 4), where they are reduced to hydrogen molecules according to reaction (2) described above.

Simultaneously, on the rear surface of the anode flow field plate (shown in FIG. 3B), coolant enters the anode coolant inlet manifold aperture 138, flows through the flow channels 191 and ultimately exits the coolant flow field 144 via the anode coolant outlet manifold aperture 139. Specifically, the coolant flows from the coolant inlet manifold aperture 138 into the first straight portions 191 a of the coolant flow channels 191. The coolant then flows through the tortuous portions 191 b and the arc portions 191 c, and subsequently through the second straight portions 191 d into the coolant outlet manifold aperture 139.

Referring now to FIG. 4, illustrated is a front surface of a cathode flow field plate 230 that includes a similar arrangement of features to those of the anode flow field plate 220. In this particular embodiment, the front surface of the cathode flow field plate 230 has substantially the same arrangement as the anode flow field plate 220. The combination of the two plates will be discussed further below.

The cathode flow field plate 230 is circular and has a central region 301 and a peripheral region 302 surrounding the central region 301. In this particular embodiment, the peripheral region 302 includes six manifold apertures. Three of the six manifold apertures are used for inputs. There is a cathode water inlet manifold aperture 156, a cathode coolant inlet manifold aperture 158, and a second cathode water inlet manifold aperture 160. The other three manifold apertures are used for complementary outputs. There is a cathode water/oxygen outlet manifold aperture 157, a cathode coolant outlet manifold aperture 159 and a cathode water/hydrogen outlet manifold aperture 161. In some embodiments, the cathode water inlet manifold aperture 160 and the water/hydrogen outlet manifold aperture 161 are both used as outputs for hydrogen produced in a respective electrolyzer cell.

A number of through holes 231 are also provided in the peripheral region 302 through which tie rods (not shown) can pass through to secure an electrolyzer cell stack together.

The front surface of the cathode flow field plate 230 is provided with a hydrogen flow field 142 comprising a plurality of open-faced channels. The flow field 142 fluidly connects the manifold apertures 156, 157 to one another. However, the combination of hydrogen and water does not flow directly from the flow field 142 to or from the manifold apertures 160, 161 directly over the front surface of the cathode flow field plate 230. The hydrogen flow between the flow field 142 and the manifold apertures 160, 161, respectively, will be described in more detail below.

On the cathode flow field plate 230 sets of slots 180, 180′ are provided adjacent the second water inlet manifold aperture 160 and the water/hydrogen outlet manifold aperture 161, respectively. The sets of slots 180, 180′ penetrate the thickness of the cathode flow field plate 230, thereby providing fluid communication between the front and rear surfaces of the cathode flow field plate 230. Specifically, the sets of slots 180, 180′ are in direct fluid communication with the flow field 142 on the front surface of the cathode flow field plate 230, and in direct fluid communication with manifold apertures 160, 161 on the rear surface of the cathode flow field plate 230.

Each set of slots 180, 180′ is shown as a collection of multiple apertures. However, in other embodiments each set of slots 180, 180′ can be provided as a single aperture. With reference to the applicant's co-pending U.S. application Ser. No. 09/855,018, the sets of slots 180, 180′ are otherwise known as “back-side feed” apertures.

A sealing surface 300 is provided around the flow field 142 and the various manifold apertures 156-161. The sealing surface 300 accommodates a seal to prevent leaking or mixing process gases/fluids. The sealing surface 300 is arranged to completely separate the various manifold apertures 156-161 from one another and the flow field 142. The sealing surface 300 may have varied depth (in the direction perpendicular to the plane of FIG. 4) and/or width (in the plane of FIG. 4) at different positions around the cathode flow field plate 230.

In this particular embodiment, the rear surface of the cathode flow field plate 230 is substantially flat and will not be described in detail herein. Those skilled in the art will appreciate that the through holes 221, the slots 180, 180′ and the various manifold apertures 156-161 penetrate the thickness of the cathode flow field plate 230. Accordingly, only these features will be noticeable on the rear surface of the cathode flow field plate, unless it is very thin.

In operation, water flows through the slots 180 leaving the rear surface and enters the flow channels of the flow field 142 on the front surface of the cathode flow field plate 230. As the water flows along the flow channels of the flow field 142, it hydrates the cathode side of an electrolyte (e.g. an electrolyte membrane). Those skilled in the art will appreciate that, during operation, the hydrogen ions migrate across an electrolyte layer to the cathode flow field plate 230, where they are reduced to hydrogen molecules according to reaction (2) described above. A combination of water and hydrogen leaves the front surface of the cathode flow field plate 230 via the slots 180′.

In some embodiments, when an electrochemical cell stack is assembled, the rear surface of an anode flow field plate of one electrochemical cell abuts against that of a cathode flow field plate of an adjacent electrochemical cell. The various manifold apertures are arranged to align with one another to form ducts or elongate channels extending through the electrochemical cell stack that, at their ends, are fluidly connectable to respective ports included on one or more of the end-plates.

With specific reference to FIGS. 3B and 4, the anode and cathode flow field plates 220, 230 have rear surfaces designed to abut one another. Moreover, on the anode flow field plate 220 and the cathode flow field plate 230 the various manifold apertures 136-141 and 156-161, respectively, align with one another to form six ducts or elongate channels extending through the electrochemical cell stack.

In some embodiments, a seal is arranged between the sealing surface 400 on the rear surface of anode flow field plate 220 and the smooth rear surface of the cathode flow field plate 230 to achieve sealing between the two plates. Subsequently, the manifold apertures 160, 161 of the cathode flow field plate 230 and the respective sets of aperture extensions 181, 181′ of the anode flow field plate 220 respectively define two corresponding chambers with distinct portions of the rear surface of the cathode flow field plate 230.

In a similar arrangement, the manifold apertures 136, 137 and the respective aperture extensions 281, 281′ of the anode flow field plate 220 respectively define two other chambers with the other distinct portions of the rear surface of the cathode flow field plate 230.

With reference to FIGS. 3A-3H and 4A, in operation water flows through the duct formed by the anode and cathode manifold apertures 136 and 156, and flows to the aforementioned chambers defined by the rear surfaces of the anode and cathode flow field plates 220, 230. For each electrolyzer cell, the water flows onto the front surface of the anode flow field plates 220, as described above. Once a combination of water and oxygen exits an electrolyzer cell it flows through the duct formed by the anode and cathode manifold apertures 137 and 157, and leaves the electrolyzer cell stack.

Similarly, water also flows through the duct formed by the anode and cathode manifold apertures 140 and 160 to the other aforementioned chambers defined by the rear surfaces of the anode and cathode flow field plates 220, 230. Then for each electrolyzer cell the water flows onto the front surface of the respective cathode flow field plate 230, as described above. Once a combination of water and hydrogen exits an electrolyzer cell it flows through the duct formed by the anode and cathode manifold apertures 141 and 161 and leaves the electrolyzer cell stack.

In one alternative embodiment, for example, the sets of aperture extensions 181, 181′ and the respective sets of protrusions 182, 182′ are arranged on the rear surface of the cathode flow field plate 230, instead of on the rear surface of the anode flow field plate 220. In such embodiments, a sealing surface is provided on the rear surface of the cathode flow field plate 230 and is configured such that it collectively encloses the manifold apertures 160, 161 and the associated sets of aperture extensions 181, 181′, the respective set of protrusions 182, 182′ as well as the corresponding slots 180, 180′.

As another alternative, the sets of aperture extensions for a particular process gas/fluid are provided on the rear surface of a flow field plate that produces the particular process gas/fluid, during operation, on its front surface. Accordingly, sets of slots can be provided in each plate that fluidly connect the front surface of the flow field plate to the rear surface of the flow field plate.

In another alternative embodiment, each of the anode and cathode flow field plates is provided with sets of aperture extensions for both the water/oxygen flow and the water/hydrogen flow. In effect, an extension chamber would then be provided, partly in one of the plates and partly in the other of the plates, extending from the respective manifold aperture(s), towards slots extending through to the front surface of a flow field plate. This configuration may be desirable where the thickness of each of the flow field plates is reduced.

In other embodiments, the anode and cathode flow field plates are identical. In such embodiments, it may be desirable to provide coolant channels on each of the anode and cathode flow field plates half the depth of the coolant channels in the case where only the rear surface of the anode flow field plate is provided with a coolant flow field. This would maintain the same amount of space for coolant flow, yet make it possible to make each flow field plate thinner. Moreover, if the anode and the cathode flow field plates are identical, as may be the case in some embodiments, a single flow field plate design can be used to make up all the cells of a stack. This simplification may in turn lead to a simplification in production steps, which may lead to lower manufacturing costs and shorter assembly times.

In related embodiments, in order to ensure that the manifold apertures on flow field plates align when an electrochemical cell stack is assembled, the manifold apertures will not only have the same dimensions, but they are also symmetrically arranged with respect to a virtual axis of the flow field plate. Understandably, the coolant apertures also have to align when the stack is assembled. This also means that the coolant apertures are also symmetrically arranged with respect to the same virtual axis.

Referring now to FIG. 5, illustrated is an enlarged simplified sectional view of an electrolyzer cell 500. The electrolyzer cell 500 includes an anode flow field plate 512, a cathode flow field plate 513 and a Membrane Electrode Assembly (MEA) 514 arranged between the anode and cathode flow field plates 512, 513. Additionally, a GDM 515 arranged between the cathode flow field plate 513 and the MEA 514. The electrolyzer cell 500 also includes two flat screens 516, 517 that are arranged between the anode flow field plate 512 and the MEA 514. Typically, the shape of the screens 516, 517 conform to the shape of the flow field plates employed. The screens 516, 517 are described in more detail below with reference to FIGS. 6A-7B.

In this particular example, the anode and cathode flow field plates 512, 513 are substantially identical to one another. Accordingly, open-faced flow field channels 522 on the anode flow field plate 512 align with open-faced flow field channels 523 on the cathode flow field plate 513. Recall, that this type of arrangement is referred to as “rib-to-rib” pattern matching as described in the applicant's co-pending U.S. patent application Ser. No. 10/109,002 that was incorporated by reference above.

In operation, on the anode side of the MEA 514 water is spread across the area of the anode flow field plate 512 as it flows through the flow field channels 522. Some of the water filters through the second and first screens 517, 516, in sequence, and reacts at the surface of the MEA 514. As described in detail above, oxygen is produced on the anode side of the MEA 514 according to reaction (1). The oxygen, typically dissolved in water, as described above, travels from the surface of the MEA 514 in sequence back through the first and second screens 516, 517 and then into the flow field channels 522. Subsequently, product oxygen and unreacted water exit the electrolyzer cell 500 through respective manifold apertures (not shown) on the anode flow field plate 512. The transport of oxygen from anode surface of MEA 514, through the first and second screens 516, 517, to the respective manifold apertures on the anode flow field plate 512 is considerably more efficient than using multiple conventional screens, in which oxygen has to travel through entangled openings of the conventional woven screens.

Similarly, on the cathode side of the MEA 514, water is spread across the area of the cathode flow field plate 513 through the flow field channels 523. As described in detail above, hydrogen is produced on the cathode side of the MEA 514 according to reaction (2). The hydrogen, typically dissolved in water, travels through the GDM 515 from the surface of the MEA 514 to the flow field channels 523. Subsequently, product hydrogen and unreacted water exit the electrolyzer cell 500 through other respective manifold apertures (not shown) on the cathode flow field plate 513.

Referring now to FIGS. 6A-7B, in some embodiments, in order to provide a more robust structure, the second screen 517 is thicker than the first screen 516. Specifically, in some embodiments the first screen 516 has a thickness of about 0.003 inches or less and the second screen 517 has a thickness of about 0.01 inches or less. Additionally, it is preferable that both of the screens 516, 517 be smooth and flat so that portions of either screen do not puncture the membrane of an assembled electrolyzer cell. Moreover, flat screens do not provide the same impediment to flow as the conventional layers of woven screens described above.

With further reference to FIG. 5, in some embodiments, in order to provide a relatively unimpeded path for the flow of water and oxygen on the anode side of the MEA 514, the size of the openings in the second screen 517 is larger than the size of the openings in the first screen 516. Shown as an example only, a first opening on the first screen 513 is indicated generally by 530 in FIG. 6B, and, similarly, a second opening is indicated generally by 540 in FIG. 7B.

With further specific reference to FIG. 6B, in some embodiments, the first flat screen 516 has openings sized from 0.004″-0.025″. As illustrated for example only in FIG. 6B, the first screen 516 has hexagonal shaped openings (e.g. opening 530) with an area of 2.49×10⁻⁴ sq in and a spacing of 0.017″ between parallel sides. Additionally, the spacing between openings on the first screen 516 is about 0.005 inches or less.

With further specific reference to FIG. 7B, in some embodiments, the second flat screen 517 has openings sized from 0.020″-0.040″. As illustrated for example only, the second screen 517 has hexagonal shaped openings (e.g. opening 540) with an area of 5.57×10⁻⁴ sq in and a spacing of 0.0254″ between parallel sides. Additionally, the spacing between openings on the second screen 517 is about 0.01 inches or less.

In some embodiments, the spacing between openings on the first screen 516 is less than the spacing between openings on the second screen 517 (e.g. 0.005″ vs. 0.010″ as illustrated in FIGS. 6B and 7B). This may be done intentionally so that the first screen 516, which is in direct contact with the MEA 514, has more open area and hence better mass transport properties. That is, water has more space to flow through the first screen 516 and surface area on which to react. The second screen 517, which is arranged between the first screen 516 and the flow field plate 512, has a thicker spacing that provides more mechanical strength to support second screen 517 from collapsing into the flow field channels 522, and provides a thicker electrical conductor for planar electron conduction throughout the second screen 517 and to the anode flow field plate 512.

In some embodiments both the first and second screens 516, 517 have a respective solid edge around the openings. The respective solid edges prevent the peripheries of the screens 516, 517 from bending into the flow field channels 522 of the anode flow field plate 512 when the electrolyzer cell 500 is assembled, which would in turn block some of the flow channels 522. The respective solid edges also provide mechanical/structural support for the screens 516, 517 and also prevent the edges of the screens 516, 517 from puncturing the MEA 514 during the assembly.

Although an example embodiment of the dual screen arrangement for an electrolyzer cell has been described, those skilled in the art would appreciate that one or both of the screens 516, 517, may, in alternative embodiments, be replaced with a porous metal layer having relatively smooth and flat faces. For example, one or both screens 516, 517 may be replaced with respective sinter layers. Moreover, in other alternative embodiments, the GDM 515 on the cathode side of the MEA 514 may also be replaced with a dual screen configuration in order to improve water and/or hydrogen flow on the cathode side of the MEA 514 and possibly improve electrical conductivity between the MEA 514 and the cathode flow field plate 513.

While the above description provides examples according to aspects of embodiments of the invention, it will be appreciated that the present invention is susceptible to modification and change without departing from the fair meaning and scope of the accompanying claims. Accordingly, what has been described is merely illustrative of the application of some aspects of embodiments of the invention. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. 

1. An electrolyzer cell comprising: an anode flow field plate; a cathode flow field plate; an electrolyte layer arranged between the anode and cathode flow field plates; and, first and second screens arranged between the anode flow field plate and the electrolyte layer, wherein each of the screens has a respective number of openings and is electrically conductive.
 2. An electrolyzer cell according to claim 1, wherein the first screen is adjacent the electrolyte layer.
 3. An electrolyzer cell according to claim 2, wherein the openings of the first screen are smaller than those of the second screen.
 4. An electrolyzer cell according to claim 3, wherein the spacing between the openings of the first screen is less than the spacing between the openings of the second screen.
 5. An electrolyzer cell according to claim 1, wherein the size of the openings of the first screen is in the range of 0.004″-0.025″.
 6. An electrolyzer cell according to claim 5, wherein the size of the openings of the second screen is in the range of 0.020″-0.040″.
 7. An electrolyzer cell according to claim 1, wherein the first screen is thinner than the second screen.
 8. An electrolyzer cell according to claim 1, wherein the thickness of the first screen is less than or equal to 0.003 inches.
 9. An electrolyzer cell according to claim 8, wherein the thickness of the second screen is less than or equal to 0.01 inches.
 10. An electrolyzer cell according to claim 1, wherein the openings of the first and second screens have a shape that is at least one hexagonal, circular, square, and triangular.
 11. An electrolyzer cell according to claim 1, wherein a maximum dimension of the openings of the first screen is approximately 0.017 inches.
 12. An electrolyzer cell according to claim 11, wherein a maximum dimension of the openings of the second screen is approximately 0.0254 inches.
 13. An electrolyzer cell according to claim 1, wherein the spacing between the openings of the first screen is less than or equal to 0.005 inches.
 14. An electrolyzer cell according to claim 13, wherein the spacing between the openings of the second screen is less than or equal to 0.01 inches.
 15. An electrolyzer cell according to claim 1, wherein at least one of the anode flow field plate and the cathode flow field plate comprises: a plurality of manifold apertures; and, a flow field, fluidly connecting two of the manifold apertures, having a plurality of open-faced flow channels that are all substantially the same length and arranged to uniformly distribute both a first process gas/fluid and heat produced by an electrochemical reaction involving the first process gas/fluid over an area covered by the flow field.
 16. An electrolyzer cell according to claim 15, wherein some of the manifold apertures have the same area.
 17. An electrolyzer cell according to claim 15, wherein some of the manifold apertures have the same dimensions.
 18. An electrolyzer cell according to claim 15, wherein the anode and cathode flow field plates are circular in shape and each has a central region and a peripheral region surrounding the central region, wherein a flow field is arranged within the central region and the plurality of manifold apertures is arranged in the peripheral region.
 19. An electrolyzer cell according to claim 18, wherein each of the open-faced flow channels include, in sequence, a first straight portion in fluid communication with a first one of the manifold apertures, a tortuous portion, an arc portion, and a second straight portion in fluid communication with a second one of the manifold apertures.
 20. An electrolyzer cell according to claim 15, wherein the anode and cathode flow field plates are rectangular in shape and the open-faced channels are comprised of a plurality of substantially straight and parallel primary flow channels that extend along the length of the flow field plate.
 21. An electrolyzer cell according to claim 15, wherein some of the manifold apertures are used to supply or evacuate process gases/fluids and each of these manifold apertures has substantially the same area as the other manifold apertures also used to supply or evacuate process gases/fluids.
 22. An electrolyzer cell according to claim 21, wherein all of the manifold apertures used to supply or evacuate respective process gases/fluids also have substantially identical dimensions.
 23. An electrolyzer cell according to claim 1, wherein at least one of the anode and cathode flow field plates comprises: a coolant flow field, on a rear surface, having a plurality of open-faced flow channels that are all substantially the same length and arranged to uniformly distribute coolant on the rear surface.
 24. An electrolyzer cell according to claim 1, wherein at least one of the anode and cathode flow field plates comprises: a first slot, extending through the flow field plate, that is in fluid communication with open-faced flow channels on a front surface and in fluid communication with a first manifold aperture on a rear surface; and, a second slot, extending through the flow field plate, that is in fluid communication with the open-faced flow channels on the front surface and in fluid communication with a second manifold aperture on the rear surface.
 25. An electrolyzer cell according to claim 24, wherein at least one of the anode and cathode flow field plates comprises: a first set of aperture extensions extending from the first manifold aperture to the first slot, over a portion of the rear surface; and, a second set of aperture extensions extending from the second manifold aperture to the second slot, over a portion of the rear surface.
 26. An electrochemical cell comprising: a first flow field plate; a second flow field plate; an electrolyte layer arranged between the first and second flow field plates; and, first and second screens arranged between the first flow field plate and the electrolyte layer, wherein each of the screens has a respective number of openings.
 27. An electrochemical cell stack, having at least one electrochemical cell comprising: a first flow field plate; a second flow field plate; an electrolyte layer arranged between the first and second flow field plates; and, first and second screens arranged between the first flow field plate and the electrolyte layer, wherein each of the screens has a respective number of openings.
 28. An electrochemical cell stack according to claim 27, wherein at least one of the first and second flow field plates comprises: a plurality of manifold apertures; and, a flow field, fluidly connecting two of the manifold apertures, having a plurality of open-faced flow channels that are all substantially the same length and arranged to uniformly distribute both a first process gas/fluid and heat produced by an electrochemical reaction involving the first process gas/fluid over an area covered by the flow field.
 29. An electrochemical cell stack according to claim 28, wherein some of the manifold apertures have the same area.
 30. An electrochemical cell stack according to claim 28, wherein the first and second flow field plates are circular in shape and each has a central region and a peripheral region surrounding the central region, wherein a flow field is arranged within the central region and the plurality of manifold apertures are arranged in the peripheral region.
 31. An electrochemical cell stack according to claim 30, wherein each of the open-faced flow channels include, in sequence, a first straight portion in fluid communication with a first one of the manifold apertures, a tortuous portion, an arc portion, and a second straight portion in fluid communication with a second one of the manifold apertures.
 32. An electrochemical cell stack according to claim 28, wherein the first and second flow field plates are rectangular in shape and the open-faced flow channels are comprised of a plurality of substantially straight and parallel primary flow channels that extend along the length of the flow field plate.
 33. An electrochemical cell stack according to claim 28, wherein some of the manifold apertures are used to supply or evacuate process gases/fluids and each of these manifold apertures has substantially the same area as the other manifold apertures also used to supply or evacuate process gases/fluids.
 34. An electrochemical cell stack according to claim 33, wherein all of the manifold apertures used to supply or evacuate respective process gases/fluids also have substantially identical dimensions.
 35. An electrochemical cell stack according to claim 28, wherein at least one of the first and second flow field plates comprises: a coolant flow field, on a rear surface, having a plurality of open-faced flow channels that are all substantially the same length and arranged to uniformly distribute coolant on the rear surface.
 36. An electrochemical cell stack according to claim 28, wherein at least one of the first and second flow field plates comprises: a first slot, extending through the flow field plate, that is in fluid communication with open-faced flow channels on a front surface and in fluid communication with a first manifold aperture on a rear surface; and a second slot, extending through the flow field plate, that is in fluid communication with the open-faced flow channels on the front surface and in fluid communication with a second manifold aperture on the rear surface. 